Flow-Responsive, Self-Adjusting Sediment Control Wattle

ABSTRACT

A sediment control device for attachment to a surface with liquid flow moving in a flow direction includes a base fastenable to the surface, the base including a trailing portion, a central portion adjacent the trailing portion, and a distal portion adjacent the central portion; a first core located at the central portion; a second core located at the distal portion; a fastening element for fastening the base to the surface with the trailing portion in a downstream location and the distal portion in an upstream location relative to the flow direction, the fastening element being vertically aligned with the first core; and the base movable from a first position in which the second core is generally horizontally adjacent the first core along the surface to a second position in which the second core is generally vertically raised relative to the first core and the surface.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a Non-Provisional Patent Application and claims priority to U.S. Provisional Patent Application Ser. No. 62/979,672, filed Feb. 21, 2020, which is incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates generally to sediment control devices and more particularly to sediment control devices such as wattles that have self-adjusting height under differing flow conditions.

BACKGROUND

Devices are employed around construction sites, for example, to control flow of water and capture sediment to protect water quality. The devices direct water and any entrained solids in a desired direction and can reduce pollution and soil erosion. The devices may filter the water and/or direct the water to a filtration device and/or settling reservoir.

Some such devices are sometimes known as “wattles.” Many wattles are generally cylindrical, passive devices which are laid or staked along edges of areas to be protected. Wattles may be made of natural materials, synthetic materials, or combinations. In many cases, governmental regulations dictate use of sediment control devices in various locations.

While existing devices work well for their intended purposes, there is an inherent design conflict between making larger devices (capable of directing larger amounts of liquids and/or flows of greater volume and/or heights) and providing compact devices (not interfering with vehicles, workers, or pedestrians moving around in the area of the devices).

Accordingly, a sediment control device that addresses one or more drawbacks of existing devices or one or more of the above issues, that is readily manufactured and installed, that is cost effective, and/or that addresses any other issues would be welcome.

SUMMARY

According to certain aspects of the disclosure, a sediment control device for attachment to a surface with liquid flow moving in a flow direction includes a base fastenable to the surface, the base including a trailing portion, a central portion adjacent the trailing portion, and a distal portion adjacent the central portion; a first core located at the central portion; a second core located at the distal portion; a fastening element for fastening the base to the surface with the trailing portion in a downstream location and the distal portion in an upstream location relative to the flow direction, the fastening element being vertically aligned with the first core; and the base configured from a flexible material so as to be movable from a first position in which the second core is generally horizontally adjacent the first core along the surface to a second position in which the second core is generally vertically raised relative to the first core and the surface. Various options and modifications are possible.

For example, the second core may define a first maximum height above the surface when in the first position and may define a second maximum height above the surface when in the second position, the second maximum height being greater than the first maximum height. The second maximum height is at least about 1.5 or 2.0 times the first maximum height. The first maximum height may be about 2.0-3.0 inches and the second maximum height may be about 4.0-6.0 inches. When the base is in the first position, the second core may have a width and a height, the width being at least about 1.5 times the height. When the base is in the second position, the second core may be atop the first core, and/or the second core may have a width and a height, the height being at least about 1.5 times the width. Also, when the base is in the first position, the first core may have a height and the second core has a height and a width, the height and the width of the second core both being greater than the height of the first core.

If desired, the base may be formed of a sheet of a geotextile fabric. The sheet may have a first end at the trailing portion and a second end at the trailing portion, the sheet being joined to itself along a seam proximate the first end and the second end, and also being joined to itself so as to be configured with a living hinge along and between the central portion and the distal portion, the seam and the living hinge defining a first pocket in the sheet, the living hinge defining a second pocket in the sheet, the first core located in the first pocket, the second core located in the second pocket. The second core may pivot about 90 degrees via the living hinge when the base moves from the first position to the second position. The base may have a first lateral edge and a second lateral edge, and the first core and the second core may each be formed in at least two sections spaced on opposite sides of a fold line extending perpendicular to the surface when the base is in the first position so that the base is foldable at the fold line for non-linear installation of the base along the surface. The at least two sections may include four sections with three of the fold lines interleaved between the four sections. The first pocket may be divided into parts by lateral seams extending between the seam and the living hinge, each part of the first pocket holding a respective one of the sections of the first core. The trailing portion may include a notch generally aligned with the fold line for influencing the foldability of the base at the notch.

The second core may include a closed cell foam with a specific gravity lower than a specific gravity of water, if so, the specific gravity of the second core may be about 0.03 g/cc.

The first core may include a strip made of a polymer, which may be formed with a cross-section of about 0.25 in.×1.50 in., and the polymer may be high density polyethylene.

The fastening element may include at least one rigid fastener extending through the base and the first core into the surface, and/or the fastening element may include an adhesive fastener on a bottom side of the base beneath the first core. The adhesive fastener may include at least one of a liquid adhesive and an adhesive tape. The base may have a first lateral edge and a second lateral edge, the adhesive fastener extending along a direction between the first lateral edge and the second lateral edge to provide a seal between the bottom side of the base and the surface. Also, the first core and the second core may each includes a lateral end spaced inwardly from one of the first lateral edge and the second lateral edge by an overlap distance so that multiple sediment control devices may be adjacently attached to the surface with the respected bases, the respective first cores, and the respective second cores substantially aligned with an amount of overlap substantially equal to the overlap distance.

According to other aspects of the disclosure, a sediment control device for attachment to a surface with a self-adjusting barrier height above the surface depending on an amount of liquid flow moving in a flow direction along the surface includes a base fastenable to the surface, the base including a trailing portion, a central portion adjacent the trailing portion, and a distal portion adjacent the central portion; a first core located at the central portion; a second core located at the distal portion; a fastening element for fastening the base to the surface along the first core with the trailing portion in a downstream location and the distal portion in an upstream location relative to the flow direction. The base is configured from a material so as to be movable, so that: before impact of a liquid flow in the flow direction, the base is in a first position in which the second core is generally adjacent the first core along the surface and the second core has a first maximum height; and upon impact of a liquid flow in the flow direction, the base is in a second position in which the second core is generally vertically raised relative to the first core and above the surface and the second core has a second maximum height at least 1.5 times the first maximum height. Various options and modifications are possible.

For example, when the base is in the first position, the second core may have a width and a height, the width being at least about 1.5 times the height. Also, when the base is in the second position, the second core may be atop the first core, and/or the second core may have a width and a height, the height being at least about 1.5 times the width.

The base may be formed of a sheet of a geotextile fabric, the sheet having a first end at the trailing portion and a second end at the trailing portion, the sheet being joined to itself along a seam proximate the first end and the second end, and also being joined to itself so as to be configured with a living hinge along and between the central portion and the distal portion, the seam and the living hinge defining a first pocket in the sheet, the living hinge defining a second pocket in the sheet, the first core located in the first pocket, the second core located in the second pocket. The second core may pivot about 90 degrees via the living hinge when the base moves from the first position to the second position.

The base may have a first lateral edge and a second lateral edge, the fastening element including a plurality of rigid fasteners extending through the base and the first core at locations between the first lateral edge and the second lateral edge, and/or the fastening element may include an adhesive fastener on a bottom side of the base beneath the first core extending along a direction between the first lateral edge and the second lateral edge. If so, the adhesive fastener may include at least one piece of an adhesive tape.

BRIEF DESCRIPTION OF THE DRAWINGS

More details of the present disclosure are set forth in the drawings.

FIG. 1 is an isometric view of sediment control device according to one embodiment of the disclosure.

FIG. 2 is a cross-sectional view of the sediment control device of FIG. 1.

FIG. 3 is top view of the sediment control device of FIG. 1.

FIG. 4 is a bottom view of the sediment control device of FIG. 1.

FIG. 5 is an end view of the sediment control device of FIG. 1 as installed in a first (resting) position.

FIG. 6 is an end view of the sediment control device of FIG. 1 as installed in a second (floating) position.

FIG. 7 is an end view of the sediment control device of FIG. 1 as installed in a third (stacked) position.

FIG. 8 is an isometric view showing installation of the sediment control device of FIG. 1 in a non-linear orientation.

DETAILED DESCRIPTION

Detailed reference will now be made to the drawings in which examples embodying the present disclosure are shown. The detailed description uses numeral and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure.

The drawings and detailed description provide a full and enabling description of the disclosure and the manner and process of making and using it. Each embodiment is provided by way of explanation of the subject matter not limitation thereof. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the disclosed subject matter without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment may be used with another embodiment to yield a still further embodiment.

Generally speaking, FIGS. 1-8 depict examples showing various aspects of sediment control devices. The disclosed examples are exemplary only, and various options and modifications are possible. As illustrated, the sediment control devices are attachable to a hard surface (e.g., asphalt, cement, etc.), but they could also be used if desired in soil, with a portion buried and/or staked in place. The disclosed sediment control devices are suitable for use in construction sites where water diversion is desired or required by code or statute, but could be employed in non-construction applications as well. The disclosed devices may be made from different materials than those mentioned below. The disclosed devices may be manufactured in differing shapes and dimensions depending on the location of use, potential amount of flow or peak flow, amount of solids in flow, size of solids in flow, etc. The disclosed devices may also be linear, curved, angled, rigid, flexible, bendable, etc. Multiple of the disclosed devices of identical or differing design may be used together to create larger barriers if desired. The disclosed devices may have a self-adjusting feature activated by flow, and may provide a barrier of differing height as flow increases. Thus, the devices may have a lower height, more convenient to walk to drive over, when no or little flow is present, but may move to a greater height when flow increases by virtue of floating on and/or impact from the flow. Thus, the examples disclosed below that may include one or more of the above aspects or other aspects should not be considered limiting.

As illustrated in the Figures, sediment control device 20 is attachable to a surface 22 and includes a base 24, a first core 26, a second core 28, and one or more types of fastening elements 30,32. Base 24 may be formed from at least one piece of woven or unwoven fabric, film, or other sheet-like material.

As illustrated, base 24 may be formed substantially of a single sheet 34 of a geotextile fabric, which may be a fabric woven from polypropylene slit-film tapes or other woven or non-woven fabrics suitable for outdoor use. Sheet 34 may be formed in sections attached, welded, and/or stitched together, and/or may be formed of completely overlapping or partially overlapping layers, etc. As shown, sheet 34 has a first end 36 and a second end 40 at a trailing portion 38 of base 24, generally adjacent first core 26. A first pocket 42 and a second pocket 44 are located between first end 36 and second end 40. First pocket 42 is located in a central portion 46 of base 24, and second pocket 44 is located in a distal portion 48 of base 24.

First core 26 located in first pocket 42, and second core 28 is located in second pocket 44. Each of pockets 42, 44 may extend completely or in sections across device between ends 56 and 56, and 60 and 62, respectively. As shown, a single second pocket 44 is provided, but four first pockets 42 are provided.

Each first pocket 42 has a single core 26, namely a high density polyethylene (HDPE) strip, within it. If device 20 has a width of about 120 inches, each strip may be about 0.5×1.5×24 inches, and seams 52 surrounding each first core 26 define each first pocket 42 snugly around the first cores. Seams 52 as shown are stitched, but they may also or alternatively include adhesives, welds, or other manner of joining.

The single second pocket 44 extends between ends of the device 20, and is defined by a single seam 54 running from end to end of device, and some closure seams 64 at the ends 60/62 of second pocket 44. As above, seams 54 may be stitching and/or other manners of joinder. Second pocket 44 is also generally snug around the one or more second cores 28 inserted therein.

As illustrated four second cores 44 are used, each about 24 inches long, generally aligned within second pocket 44 with the four first cores 26. If desired, a spacer, stitching, adhesive, other material, etc. may be used along, between, and/or laterally outside of the second cores 28 to maintain their general alignment with the first cores 26 within second pocket 44.

Seams 52,54 may be airtight and/or watertight, but need not be in all aspects. Ends 56,58 and 60,62 of pockets 42 and 44 may also include permanently formed or re-openable seams (not shown) for covering the ends of the pockets 42,44 and protecting and maintaining cores 26,28 therein.

Device 20 is configured for attachment to surface 22 so as to at least partially block, filter, and/or redirect a liquid flow moving in a flow direction 50 (i.e., typically a gravity-based flow in a generally “downhill” direction). Thus, surface 22 may be for example a paved subsurface or top surface of a road, parking area, patio, sidewalk, etc. Device 20 may if desired be mounted so as to face or abut a nonplanar element adjacent or atop surface 22 such as a wall, curb, barrier, grating, etc. (see, e.g., curb 66 in FIG. 8, discussed below).

Fastening elements 32 may be screws suitable for use in concrete, asphalt, or other hard surface, as surface 22. If device 20 is instead deployed in soil gravel or other surface as surface 22, fastening elements could be nails, spikes, etc. Fastening elements compress base 24 at first pocket 42 and first core 26 so that device tightly attaches to surface there. As shown, two such fastening elements 32 are provided at opposite ends of each first core 26, but more or fewer could be used. Guide holes may be formed through base 24, first core 26, and elements 30 (if a tape) to help a user locate and attach fastening elements 32 through device 20 and into surface 22.

Fastening elements 30 may be a liquid adhesive or a double-sided adhesive tape, as illustrated. Fastening elements may extend partially or fully between sides of device 20, or in sections beneath first cores 26, as illustrated. Use of such liquid adhesive or tape helps bond base 24 to surface 22, and also helps provide an at least partial leak proof seal between base and surface, so that water is at least substantially directed in the desired direction around the device, rather than passing beneath it.

Certain benefits are achievable if device 20 is fastened to surface 22 using fastening elements 30 and/or 32 with trailing portion 38 in a downstream location and distal portion 48 in an upstream location relative to flow direction 50. By “relative to flow direction 50,” it is not meant that device 20 must be laid out fully perpendicular or across a flow or a portion of a flow, just that a given flow generally impacts device 20 directly or obliquely at distal portion 48 before trailing portion 38. However, device 20 can alternatively be attached in other fashions and in other orientations relative to flow direction 50, including oppositely to that described above, in some applications.

Base 24 is configured from material(s) selected so as to be movable from a first position (FIG. 5) in which second core 28 is generally adjacent first core 26 along surface 22 to a second position (any of FIG. 6 or 7, or anything between FIG. 5 or 7 for that matter) in which second core 28 is generally vertically raised relative to first core 26 and above (i.e., spaced from) surface 22. As shown in FIG. 5, first core 26 has a height h1, second core 28 has a height h2 and a width w2, and device 20 has a maximum height of h3. The relative proportions of these dimensions in FIG. 5 are but one example that is suitable for device 20, and others are possible, as described below.

FIGS. 6 and 7 show orientation of second core 28 as flow from flow direction 50 and/or accumulation of flow increases. Note that a maximum height h3 above surface 22 of device 20 in FIG. 5 is second core 28 height h2, which is greater than first core 26 height h1. In FIG. 6, second core 28 begins to rise, central portion 46 acting as a living hinge, and device 20 has a maximum height of h3 greater than h2. Greater force or flow can topple second core 28 into a position atop first core 26, as shown in FIG. 7. Thus, height h3 of device 20 is now generally equal to h1 plus w2. Although h3 in FIG. 7 is potentially lower than in FIG. 5, the FIG. 6 orientation may be more stable in certain flow circumstances.

One benefit of having a flexible and movable device with differing heights and configurations is in providing a lower profile (i.e., shorter) device of maximum height (in this case h2), for times of no flow or light flow. Such height can be sufficient to divert light flow 50, and is also less obtrusive in terms of walking, driving, maneuvering equipment, around and/or over device 20. In particular, a benefit may be provided that vehicles can be driven more readily over device 20 with such structure if the material used for cores 26, 28 is flexible enough and or rebounds in shape, so that device 20 and or the vehicle is not undesirably damaged and/or inconvenienced.

Thus, it can be said that first and second cores 26, 28 may define a first maximum height (h2=h3 in FIG. 5) when in the first position (FIG. 5) and may define a second maximum height (h3) when in the second position (FIGS. 6-7) greater than the first maximum height. The second maximum height may be at least about 1.5 times the first maximum height, or at least about 2.0 times the first maximum height. If the first maximum height is about 3.0 inches, the second maximum height may be about 4.5 or about 6.0 inches. When in the second position, second core 28 may (but need not be) be generally vertically atop the first core, as in FIG. 7. As illustrated, h1=about 0.25 inches; h2=2.5 inches; and w2=5.0 inches, so h3 in FIG. 7=about 5.25 inches.

As shown, first and second cores 26, 28 have cross-sections that are substantially rectangular, but they have may other shapes such as triangles, trapezoids, polygons, circles, ovals, convex, concave, or other linear, curved or irregular, or combinations thereof. The cross-sections may be uniform along the entire length of cores 26, 28 or they may vary. Cores 26, 28 may be relatively rigid, relatively bendable, returnably deformable, and/or formed in two or more sections so that device 20 may be folded (angled) between the sections of the cores.

Second core 28 may include a foam, such as a water-resistant, closed-cell foam, which may be, for example, EVA, polyethylene, polystyrene, rubber, polypropylene, or other. Second core may also be organic or inorganic material, preformed or loose, held within second pocket 44. The second core may have a specific gravity lower than a specific gravity of water (e.g., generally about 1 g/cc). If a closed-cell foam, the specific gravity may be about 0.03 g/cc. The lower specific gravity allows core 28 to float upwards on flow. However, lower specific gravity than water, or specific gravity of about such level, is not required in all aspects of the disclosure.

As shown in FIG. 8, forming first and second cores 26,28 in sections that are collectively shorter than the full width of device 20 allows for bending around a generally vertical fold line 68 between individual portions of such cores. Such allows for non-linear installation as shown to selectively collect and move water and more modularity and adjustability in installation. Multiple devices can be butted up against each with first and second cores aligned or offset to create longer installations where needed. Having the cores not extend to ends of devices allows for a snug, partially overlapping installation if desired. Preferential bend portions 70, such as the illustrated triangular cutouts 68, or slits or other weekending or flexibility creating structures may be located at positions between tends of first and second cores 26,28 to assist in locating and forming desired bends

While one or more preferred embodiments have been described above, it is to be understood that any and all equivalent realizations of the disclosed subject matter are included within the scope and spirit thereof. Thus, the embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, while particular embodiments have been described and shown, it will be understood by those of ordinary skill in this art that the present invention is not limited thereto since many modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the literal or equivalent scope of the appended claims. 

1. A sediment control device for attachment to a surface with liquid flow moving in a flow direction, the sediment control device comprising: a base fastenable to the surface, the base including a trailing portion, a central portion adjacent the trailing portion, and a distal portion adjacent the central portion; a first core located at the central portion; a second core located at the distal portion; a fastening element for fastening the base to the surface with the trailing portion in a downstream location and the distal portion in an upstream location relative to the flow direction, the fastening element being vertically aligned with the first core; and the base configured from a flexible material so as to be movable from a first position in which the second core is generally horizontally adjacent the first core along the surface to a second position in which the second core is generally vertically raised relative to the first core and the surface.
 2. The sediment control device of claim 1, wherein the second core defines a first maximum height above the surface when in the first position and defines a second maximum height above the surface when in the second position, the second maximum height being greater than the first maximum height.
 3. The sediment control device of claim 1, wherein the second maximum height is at least about 1.5 times the first maximum height. 4-5. (canceled)
 6. The sediment control device of claim 1, wherein when the base is in the first position, the second core has a width and a height, the width being at least about 1.5 times the height.
 7. The sediment control device of claim 6, wherein when the base is in the second position, the second core is atop the first core.
 8. The sediment control device of claim 7, wherein when the base is in the second position, the second core has a width and a height, the height being at least about 1.5 times the width.
 9. The sediment control device of claim 1, wherein when the base is in the first position, the first core has a height and the second core has a height and a width, the height and the width of the second core both being greater than the height of the first core.
 10. The sediment control device of claim 1, wherein the base is formed of a sheet of a geotextile fabric.
 11. The sediment control device of claim 10, wherein the sheet has a first end at the trailing portion and a second end at the trailing portion, the sheet being joined to itself along a seam proximate the first end and the second end, and also being joined to itself so as to be configured with a living hinge along and between the central portion and the distal portion, the seam and the living hinge defining a first pocket in the sheet, the living hinge defining a second pocket in the sheet, the first core located in the first pocket, the second core located in the second pocket.
 12. (canceled)
 13. The sediment control device of claim 11, wherein the base has a first lateral edge and a second lateral edge, and wherein the first core and the second core are each formed in at least two sections spaced on opposite sides of a fold line extending perpendicular to the surface when the base is in the first position so that the base is foldable at the fold line for non-linear installation of the base along the surface.
 14. (canceled)
 15. The sediment control device of claim 13, wherein the first pocket is divided into parts by lateral seams extending between the seam and the living hinge, each part of the first pocket holding a respective one of the sections of the first core.
 16. (canceled)
 17. The sediment control device of claim 1, wherein the second core includes a closed cell foam with a specific gravity lower than a specific gravity of water.
 18. (canceled)
 19. The sediment control device of claim 1, wherein the first core includes a strip made of a polymer. 20-21. (canceled)
 22. The sediment control device of claim 1, wherein the fastening element includes an adhesive fastener on a bottom side of the base beneath the first core.
 23. (canceled)
 24. The sediment control device of claim 22, wherein the base has a first lateral edge and a second lateral edge, and the adhesive fastener extends along a direction between the first lateral edge and the second lateral edge to provide a seal between the bottom side of the base and the surface.
 25. The sediment control device of claim 1, wherein the base has a first lateral edge and a second lateral edge, the first core and the second core each including a lateral end spaced inwardly from one of the first lateral edge and the second lateral edge by an overlap distance so that multiple sediment control devices may be adjacently attached to the surface with the respected bases, the respective first cores, and the respective second cores substantially aligned with an amount of overlap substantially equal to the overlap distance.
 26. The sediment control device of claim 1, wherein the base has a first lateral edge and a second lateral edge, the fastening element including a plurality of rigid fasteners extending through the base and the first core at locations between the first lateral edge and the second lateral edge.
 27. The sediment control device of claim 26, wherein the fastening element includes an adhesive fastener on a bottom side of the base beneath the first core extending along a direction between the first lateral edge and the second lateral edge.
 28. (canceled)
 29. A sediment control device for attachment to a surface with a self-adjusting barrier height above the surface depending on an amount of liquid flow moving in a flow direction along the surface, the sediment control device comprising: a base fastenable to the surface, the base including a trailing portion, a central portion adjacent the trailing portion, and a distal portion adjacent the central portion; a first core located at the central portion; a second core located at the distal portion; a fastening element for fastening the base to the surface along the first core with the trailing portion in a downstream location and the distal portion in an upstream location relative to the flow direction; and the base configured from a material so as to be movable wherein: before impact of a liquid flow in the flow direction, the base is in a first position in which the second core is generally adjacent the first core along the surface and the second core has a first maximum height; and upon impact of a liquid flow in the flow direction, the base is in a second position in which the second core is generally vertically raised relative to the first core and above the surface and the second core has a second maximum height at least 1.5 times the first maximum height.
 30. The sediment control device of claim 29, wherein when the base is in the first position, the second core has a width and a height, the width being at least about 1.5 times the height.
 31. The sediment control device of claim 30, wherein when the base is in the second position, the second core is atop the first core.
 32. The sediment control device of claim 31, wherein when the base is in the second position, the second core has a width and a height, the height being at least about 1.5 times the width.
 33. The sediment control device of claim 29, wherein the base is formed of a sheet of a geotextile fabric, the sheet having a first end at the trailing portion and a second end at the trailing portion, the sheet being joined to itself along a seam proximate the first end and the second end, and also being joined to itself so as to be configured with a living hinge along and between the central portion and the distal portion, the seam and the living hinge defining a first pocket in the sheet, the living hinge defining a second pocket in the sheet, the first core located in the first pocket, the second core located in the second pocket.
 34. The sediment control device of claim 33, wherein the second core pivots about 90 degrees via the living hinge when the base moves from the first position to the second position. 